In 2017 and subsequently 2018, IEA completed digital control upgrades on two bussed together diesel generators and a single engine generator. All engines were nineties vintage Caterpillar Diesel engine generators.

Problem: The old control system was showing its age; frequent relay failures, mechanical timer failures, and physical fatigue failures at termination points (terminal strips, relay bases, sensors, and splices). This drastically reduced system reliability, which is not where the customer or IEA wanted to be.

Solution: A new control system including all new digital generator controls, digital Automatic Transfer Switches (ATS), new interconnecting cabling, and a new digital voltage regulator for the single engine.

Result: The system has proven to be highly reliable, with the added benefit of increased diagnostics for troubleshooting via the remote Programmable Logic Controller (PLC), and the number of potential failure points were significantly reduced by the new digital equipment and software.

These projects were completed in the field in about three weeks working double shifts, six days per week, and about one week working single shifts respectively.